Check the bushing for excessive wear or scratches. Check the spring for fatigue or damage.

Check the compression adjuster for clicks.

Replace the fork cap as an assembly if necessary.

dГЯ

Apply fork oil to new O-rings and install them.

FORK CENTER BOLT

ADJUSTER ROD

CENTER BOLT

Check the fork center bolt for damage.

Check the adjuster rod for stepped wear or damage. Check the rebound adjuster for clicks.

Replace the fork center bolt as an assembly if neces­sary.

Apply fork oil to a new O-ring and install it.

SLIDER/OUTER TUBE

Check the outer tube and slider for score marks, scratches and excessive or abnormal wear.

Check the outer tube for damage or bend.

Set the slider on V-blocks and measure the runout.

Turn the slider and measure the runout using a dial 05 ~ shown indicator.

SLIDER

Actual runout is 1/2 of the total indicator reading.

SERVICE LIMIT: 0.20 mm (0.008 in)

Do not reuse the slider if it is bent.

Replace if the service limit is exceeded, or there are scratches or nicks that will allow fork oil to leak past the seals.

FORK SPRING

Measure the fork spring free length by placing it on a flat surface.

SERVICE LIMIT: 493 mm (19.4 in)

BUSHING/BACK-UP RING

BUSHING

Check the bushing for excessive wear or scratches. If copper appears on the surface, replace the bush­ing.

Replace the back-up ring if there is distortion at the points shown.

Remove any metal powder from the slider and guide bushings with a nylon brush and fork oil.

BACK-UP RING

FORK DAMPER

PISTON ROD

’05 — ’07 shown:

FORK DAMPER

Check the fork damper for bends or damage.

Check the fork damper piston rod for bends, wear or damage.

Check the fork damper operation by pumping the piston rod.

If the operation is not smooth, fill the fork damper with fork oil and check the fork damper operation again (page 14-25).

ASSEMBLY

05 — ’07 shown

SLIDER BUSHING

SLIDER

PLUG BOLT

OUTER TUBE

FORK CAP

GUIDE BUSHING

•a O-RINGS

FORK DAMPER

PUSH ROD

O-RING

CENTER BOLT

/ DUST SEAL / 7

ф у/ j j / j J *ШШ BACK-UP RING

FORK SPRING WEAR STOPPER RING

Before assembly, wash all parts with a high flash­point or non-flammable solvent and wipe them dry.

OUTER TUBE AND SLIDER ASSEMBLY

Wrap the end of the slider with tape. m ічт тдрс

Coat new oil seal and dust seal lips with fork oil. / / "

Install the dust seal and stopper ring onto the slider.

Install the oil seal onto the slider with its marked

side facing the dust seal. 1

Remove the tape from the end of the slider.

STOPPER RING

GUIDE BUSHING

Be careful not to damage the slider bushing coating. Do not open the slider bushing more than necessary.

Install the back-up ring, guide bushing and slider bushing.

NOTE:

SLIDER BUSHING BACK-UP RING

Remove the burrs from the bushing mating surface, being careful not to peel off the coating.

Coat the slider and guide bushings with fork oil and install the slider into the outer tube.

’05 — ’07 shown:

07VMD-KZ30100 or 07VMD-KZ3010A (U. S.A. only)

SLIDER

DUST SEAL

Drive in the guide bushing together with the back­up ring into the outer tube using the special tool. Drive the oil seal into the outer tube using the spe­cial tool.

TOOL:

Install the stopper ring into the groove in the outer tube.

Install the dust seal.

FORK DAMPER FORK CAP ASSEMBLY

THREADS

FORK DAMPER REFILLING/ASSEMBLY

Clean the fork cap assembly and fork damper threads.

Fork seal driver, 47 mm

Extend the fork damper piston rod to its maximum length.

FORK DAMPER

Pour the recommended fork oil into the fork damper.

RECOMMENDED FORK OIL:

Pro Honda HP Fork Oil 5W or equivalent

STANDARD CAPACITY:

192 cm3 (6.5 US oz, 6.8 Imp oz)

Be careful not to damage the fork cap bushing.

Apply fork oil to the bushing and new О-rings on the

O-RINGS

FORK DAMPER

fork cap assembly. 4га

Extend the fork damper piston rod to maximum.

Hold the rod end, install the fork cap assembly into the fork damper.

If it is difficult to install the fork cap assembly, the fork damper oil level might be higher than standard.

Inspect the fork damper oil level again.

Set the fork damper in a vise with a piece of wood or soft jaws to avoid damage.

Do nor over-hghten the vise.

FORK DAMPER FORK CAP ASSEMBLY

Tighten the fork cap assembly to the specified torque by holding the fork damper using the special tool.

TOOL:

Lock nut wrench, 50 mm 07WMA-KZ30100

TORQUE: 30 N m (3.1 kgf-m, 22 Ibf ft)

Hold the fork damper in an upright position and pump the fork piston rod 100 mm (3.9 in) slowly, several times.

Turn the lock nut clockwise until it is lightly seated.

NOTE:

• Set the rebound adjuster and compression adjuster counterclockwise to the softest position.

• Check the fork damper piston rod sliding surface for damage.

• Apply fork oil to the fork damper piston rod slid­ing surface.

Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked.

Cover the piston rod end with a clean shop towel to prevent damage.

Blow out any extra oil in the fork damper spring chamber by fully stroking the fork damper piston rod.

Drain the extra oil from the oil hole (After ’07: oil,

By doing this procedure, about 17 cm3 of fork fluid will be drained from the damper spring chamber through the oil hole IAfter ’07: oil holes). This will cause 7 75 cm3 of fork fluid to be left in the chamber.

’05 — ’07 shown:

holes) of the fork damper. 05 ~ 07 shown: FORK DAMPER

Blow out any oil from the oil hole (After ’07: holes) of the fork damper using compressed air.

Wipe off the oil completely from the fork damper.

FORK DAMPER

OIL HOLE

SPRING CHAMBER

oil

If you cannot use compressed air, remove the pres­sure release screw on the fork cap.

Hold the fork damper upside down for 10 minutes and drain the oil from the fork damper spring cham­ber.

Tighten the pressure release screw to the specified torque.

TORQUE: 1.2 N-m (0.1 kgf-m, 0.9 Ibf-ft)

FORK DAMPER OPERATION INSPECTION

• Turn the compression adjuster counterclockwise to the softest position.

• Check the fork damper piston rod sliding surface for damage.

• Apply fork oil to the fork damper piston rod slid­ing surface.

Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked.

Inspect the fork damper operation after air bleeding (page 14-23).

Cover the piston rod end to prevent damage.

Fully stroke the fork damper piston rod by pushing down the fork damper.

Check the fork damper piston rod for smooth opera­tion.

If the fork damper piston rod operation is not smooth, check the piston rod for bends or damage.

Hold the fork damper level while the fork damper piston rod is fully extended and compressed by hand.

FORK DAMPER

Release the fork damper piston rod then check that it extends to its maximum length.

If the fork damper piston rod does not extend to maximum, bleed the fork damper again.

Wipe the oil completely off from the fork damper. Compress the fork piston rod 200 — 250 mm (7.9 — 9.8 in) from fully extended and hold the fork damper in an upright position for 10 minutes.

There should be no oil leaking from the fork damper spring chamber and piston rod.

If oil leaks from the spring chamber or piston rod, replace the fork damper assembly.

Hold the fork damper on level ground and release the fork damper piston rod, then check that the pis­ton rod extends to its maximum length.

FORK DAMPER INSTALLATION/PREPARATION

OUTER TUBE/SLIDER

If the outer tube and slider (fork) have not been dis­assembled, turn the fork upside down for 20 min­utes and drain the oil from the inside of the outer tube and slider completely (7 cc at 20°C/ 68°F).

Amount of fork oil left in the fork (without damper and spring)

unit: cc

minute

5

10

20

35

55

85 | 145

30/86

7.1

5.9

4.7

4.2

3.5

3.5 3.5

u.

p

20/68

10.6

8.2

7.1

5.9

5.6

4.7 4.7

О

о

10/50

11.8

8.3

7.2

6.2

5.8

4.9 4.8

0/32

12.9

10.6

9.4

8.2

7.9

7.1 I 5.9

If the fork damper has not been disassembled from the outer tube/slider, turn it upside down for 20 min­utes and drain the oil from the inside of the outer tube and slider completely (12 cc at 20°C/ 68°F).

Replace the wheel Install the remover head into the bearing. bearings m pairs. From the opposite side of the wheel, install the Do not reuse old remover shaft and drive the bearing out of the bearings, wheel hub.

When removing the both fork legs, remove the steering damper to prevent damaging it (page 14­38).

Remove the following:

— Front visor (’05 — ’07: page 3-5, After ’07: page 3­6)

— Front wheel (page 14-8)

Do not suspend the brake caliper from the brake hose. Do not twist the brake hose.

Remove the mounting bolts and front brake caliper.

Do not operate the brake lever after removing the caliper and front wheel. To do so will cause diffi­culty in fitting the brake disc between the brake pad. Remove the bolts and brake hose clamp.

Remove the screws and tripmeter cable clamp.

Remove the bolts and fork protector.

Loosen the fork top bridge pinch bolts.

TOP BRIDGE PINCH BOLTS

REBOUND ADJUSTER

When the fork is ready to be disassembled, remove the handlebar and holders (page 14-32) and loosen the fork damper using the following procedure.

COMPRESSION ADJUSTER

When disassembling the fork leg, turn the rebound and compression adjusters counterclockwise to the softest position to prevent damaging the adjust­ment needle (be sure to record the number of turns from the starting position).

Do not use a crescent or adjustable wrench to loosen the fork damper; it could be damaged

LOCKNUT WRENCH

FORK

FORK DAMPER

Loosen the fork damper using the special tool, but do not remove it yet.

TOOL:

BOTTOM BRIDGE PINCH BOLTS

Lock nut wrench, 50 mm 07WMA-KZ30100

Loosen the fork bottom bridge pinch bolts and pull the fork leg down and out.